Welded engine frame construction



- Feb. 1, 1947. E. CHAPMAN 2,416,945

WELDED ENGINE FRAME CONSTRUCTION Filed May 24, 1945 4 Sheets-Sheet 1'FEGJ.

lilllllll will HUMP . INVENTOR 2 9 a H BY vre Chapman Feb. 18, 1947.

E. CHAPMAN WELDED ENGINE FRAME CONSTRUCTION Filed May 24, 1

945 4 Sheets-Shae}. 2

Feb. 1s,- 1947.- CHAPMAN 2,416,045

WELDED ENGINE FRAME CONSTRUCTION Filed May 24, 1945 4 Sheets-Sheet 3INVENTOR Euere/f Chapman ATTO EY Feb. 18, 1947. I E. CHAPMAN 2,416,045

WELDED ENGINE FRAME CONSTRUCTION Filed May 24, 1945 4 s eets-sheet 4INVENTOR Everef? Chapman ATTO Y Patented Feb. 18, 1947 WELDED ENGINEFRAME CONSTRUCTION Everett Chapman, West Chester, Pa., assignor toAmerican Locomotive Company, New York, N. Y., a corporation of New YorkApplication May 24, 1945, Serial No. 595,617

8 Claims.

This invention relates to a welded engine frame construction.

The invention relates more particularly to a welded frame constructionfor a multi-cylinder engine, the frame construction being provided withinterior rows of alignedorifices for housing the several cylinders ofthe engine. It has formerly been the practice, in building an engineframe cast construction for a multi-cylinder engine, to form it of asingle massive casting, or of even more than one massive casting. Ineither event, on account of the size of the casting required, variousproblems are presented, relating for instance to the usual foundrydefects of porosity, shrinkage and cracks, in addition to the setting upof harmful stresses, distortions, improper centering, improper spacingor positioning of parts and inaccurate over-all dimensions. The presenceof these defects sometimes renders the large and expensive castingunsuitable for use.

It is an object of the present invention to provide a frame constructionthat will avoid the presence of these defects.

A further object is to provide a construction, characterized asaforesaid, composed of a bank of similar relatively small integral unitswelded together. The units are preferably steel castings or forgings,and on account of their relatively small size and themethod of weldingpursued, the aforementioned defects are prevented and the desiredresults attained. Furthermore should a unit of the many similar unitsprovided for the bank be found defective, its loss would be a relativelysmall matter.

A further object is to provide an opposed piston engine frameconstruction comprising a bank of units of the aforesaid characteristicsand in which there are rows of aligned welded joints between oppositecrank shaft half bearing members welded to the bank, the members havinghalf bearing caps bolted thereto and the bolts of a member being each inline with a line of welded joints, thereby attaining maximum ability towithstand tension forces transmitted to the bank of units from the crankshafts.

A further object is to provide a frame con struction, as aforesaid,including a large number of similar unitary parts welded together, theparts being produceable by a repetitious system of manufacturing, suchas by forging or casting, whereby the principles of mass production canbe applied to the fabrication of one frame, thereby greatly reducing itscost, and furthermore, the production of small unitary parts instead ofa large unitary frame permits manufacture by the use of small tools andequipment, thereby further reducing the production cost.

Other and further objects of this invention will appear from thefollowing description, the accompanying drawings and the appendedclaims.

Referring to the drawings forming a part of this application, Figure 1is a side view of a portion of a frame construction embodying thepresent invention, parts being shown in section on the line 1-1 of Fig.2; Fig. 2 is a section on the line 11-11 of Fig. 1, parts being added;Fig. 3 is a section on the line III-.III of Fig. 2; Figs. 4, 5, 6 and 7are isometric views, the first three being enlarged, of groups of theintegral units showing the manner of fabricating the frame construction,Fig. 4 showing two units of a. row in position for welding, Fig. 5showing, fragmentally, two rows of welded units in position for weldingtogether, Fig. 6 showing a partial row of the completed frameconstruction, and Fig. 7 showing two adjacent partial rows of thecompleted frame construction; and Fig. 8 is an enlarged sectional viewof a portion of the completed frame constructionshowing weld flashes,taken on the line VIII-VIII of Fig. 3.

While the frame construction of the present invention is adaptable forvarious types of engines, it is more particularly adapted for internalcombustion engines. It is shown in connection With an opposed pistoninternal combustion engine for which it is especially adapted.

While the invention is not-limited to engines of the vertical type, theframe construction is shown, for convenience, as part of such a type ofengine and will be hereafter so described. Nevertheless it will beunderstood that by obvious changes within the spirit of the inventionthe frame construction may be made as a part of other types of engines,for instance as a part of a horizontal engine. I

The frame construction is further shown in connection with afour-cyclinder engine (see Fig. 3) and a row of four orifices isprovided for housingeach of the four cylinders. It will at once appearobvious from the following description that by changing the number ofintegral units in each longitudinal row of units, a construction may beprovided for a greater or less number of cylinders as may be desired,and, similarly, by changing the number of superimposed rows of integralunits the number of orifices for housing each cylinder will be changedcorrespondingly as may be desired.

by the reference numeral l, and comprises a vertical bank of integralunits, in the present instance twenty in number. The units are made eachas a single forging or casting, preferably of steel. The units of thebank will be considered as arranged in horizontal longitudinal rows, therows being superimposed one upon the other. There are four such rows andfive units in each row. The end units of each row differ slightly fromthe intermediate units, although they may be made similar to theintermediate units if desired, as will later appear.

Each unit is indicated generally by the reference numeral 2, and, asbefore stated, is integral and made as a single steel forging orcasting. Each unit comprises two spaced vertical side members 3 and ahorizontal cross member 4 connecting the side members, four gussets 5being preferably provided at the junctures of the cross member top andbottom faces with the side members to strengthen the unit.

The side members are recessed at their corners providing therebycross-like structures each having a longitudinal bar 6 and a, bar Iperpendicular to the longitudinal bar. The two bars cross each other attheir centers or, more accurately, the two barshave a common portionattheir centers. This provides two opposed longitudinal barsto whichthecross member 4 is integrally connected. and two oppositely disposedperpendicular bars extending from the plane of the cross member 4 inopposite directions. The end units of each row are shown with theirlongitudinal bars 6 somewhat shortened at their outer ends. .This,however, is a matter of choice.

The cross member 4 of each of the intermediate units is recessed at itsopposite edges providing wall sections 8 for a purpose later to bementioned. The end unitshave a wall section.

8 only at their inner edges. Their outer edges are providedwith'recesses having defining walls 9. These outer edge recesses aremostly to lighten the frame construction and they may be made .similartothe inner edge recesses having their will later appear, although, ifdesired, they may be slightly spacedand not welded. In the presentinstance they are shown welded together, as this is preferable, and willbe hereinafter so described.

It is essential that the cylindrical walls It be suitably disposed sothat their centers will be properly spaced and further that the desiredlongitudinal over-all dimension of each row of units will be attained.To this end pressure welding is resorted to and accordingly the unit ismade so that the bars 6 will have excess weldable metal l2 at their endsto be pressure welded, and the cross member 4, with its wall sections 8,(assuming they are to be welded to other wall sections 8) will haveexcess weldable metal 13 at their ends. 7

Fig. 4 shows'two adjacent units (of an unwelded longitudinal row ofunits) with their excess weldable metal 12 and l3. While the rows ofunits may be welded together by various methods in some instances,nevertheless when the cross walls of the frame construction are to bespaced in a desired manner and an over-all desired height of the frameconstruction must be attained, or in the case of an opposed pistonengine, the proper spacing between the crank shaft centers must beattained, a similar method of welding as that just described is followedin welding the aforesaid rows together. To this end the unit is made sothat the bars 1 will have excess weldable metal M at their ends to bepressure welded, as is also shown in Fig. 4.

I While it may not always be desired, it is generally preferably toprovide the recesses in the corners of the side members 3 as aforesaidas they result in the formation of the bars 6 and I. It should bementioned here that the aforesaid method of welding the units of the rowtogether insures a proper spacing of the bars 7. Furthermore therecesses in the corners of the side members 3 result in the formation ofthe large openings 15, four such recesses combining to form each ofthese openings (see Fig. 5). These openings lighten the frameconstruction, the desired strength and rigidity nevertheless beingmaintained. The openings l5 furthermore permit inspection and repair ofthe interior of the frame construction and of the various parts of theengine that will be housed therein.

Special apparatus forming no part of the present invention will beemployed for effecting pressure welding of the parts together. After theunits have been forged or cast as aforesaid they are welded together toform longitudinal rows and as the method of welding is similar for eachrow a description of forming one row will suffice.

First the end unit of the row and a unit adjacent thereto are placedwith the excess weldable metal at the adjacent edges of their bars 6 andat the adjacent edges of their cross membars 4 respectively oppositeeach other and heated to a welding temperature. The heating may beaccomplished in any desired or well-known manner, such as by electricalor flame heating. Pressure is then applied by the apparatus employed,such as a. hydraulic press welding machine. This pressure results inmoving the units together, at the same time displacing the hot excessmetal, and this pressure is continued until the centers of the adjacentwall sections 8 of the two units coincide, forming a cylindrical wall IIand at the same time accurately spacing the bars 1 thereof. Thisprovides a welded joint between the two units on each side thereof. Nextanother unit is then added to the two units of the row thus weldedtogether and the welding method repeated with like results. In likemanner each unit is added and welded to the partially completed rowuntil the longitudinal row of units is completed as shown in Fig. 3,forming a cross wall I6 of the frame construction.

Fig. 4 shows two units of a row in position for welding but here thewelding is presumed to be carried out first between two intermediateunits and progressing to the ends, instead of first between the end unitand its adjacent unit and progressing to the opposite end, which hasjust been described and which is a more desirable order to follow inassembling and welding the units of the rows.

Fig. 6 is a portion of the completed bank of units showing four weldedjoints ll of the bars 6 and four welded joints I8 of the cross members 4and their wall sections 8.

Where the rows are to be welded together by the pressure welding method,the bars 1, as aforesaid, will have been formed with the excess weldablemetal I4. The rows are welded together preferably by positioning an endrow and the adjacent row superimposed thereon so that'the center linesof their corresponding cylindrical walls coincide and theircorresponding bars 1 are in alignment. The welding is carried out in amanner similar to that already described in forming each row, namely theexcess weldable metal at the adjacent ends of the bars I is heated to awelding temperature and the pressure applied. This pressure results inmoving the rows together, at the same time displacing the hot excessweldable metal, and this pressure is continued until the two cross wallsI6 are suitably spaced. Another row is similarly placed upon thepartially completed construction and the welding carried out in asimilar manner with like results. This method is repeated withsuccessive rows until all rows are welded together. The assembling andwelding of the rows one upon another results in completing the openings|5 which were formed as half openings by the formation of the rows.

The bank of welded units is thus brought to completion. It has in thepresent instance four cross walls |6 formed by the cross members 4 andtwo side walls l9 formed by the oppositely disposed side members 3. Thefour cross walls provide four vertical rows 20 of four alignedcylindrical walls each, each row of cylindrical walls being appropriatefor housing a power cylinder. The power cylinders are not shown and theterm is used in its broad sense to include the usual cylinder liner,jacket, and other parts, as may be employed in any instance.

Fig. 5 shows, fragmentally, two rows of units in position for welding,and Fig. 7 shows a portion of the completed bank of units showing twowelded joints 2| of the bars I. As will be seen in Fig. 1 these joints2| are arranged in vertical rows, the rows of one side wall IQ of theframe construction being each opposite to a corresponding row of theother side wall l9. The disposition of these rows is such'that there aretwo opposite rows of joints 2| at each side of each row of cylindricalwalls The weld flashes 22, 23 and 24 (Fig. 8) at the joints l1, l8 and2| produced by the displaced excess weldable metals are to be removed,as by machining or grinding. Fig. 8 shows at the right a section throughthe joints i1 and I8, the section at the left being taken in advance ofthe flashes 22 and 23.

A row of crank shaft bearing members 25 for a crank shaft 26 is disposedat the bottom of the lowermost row of units and may fdrm a base for theengine. In the case of an opposed piston engine there will be, as shownin Fig. 2, another row of crank shaft bearing members 21, supported onthe upper row of units, for a second crank shaft 28. Caps 29 areprovided for shafts 26 and 28 and are secured by bolts 30 to theirrespective bearing members 25 and 21. The bearing members 25 areconnected by channel irons 3|, and bearing members 21 are connected bychannel irons 32, the connections beingpreferably made by welding.

The bearing members and their bolts at the bottom are in verticalalignment with corresponding bearing members and their bolts at the topand aligned pairs of these bolts are in alignment with correspondingaligned rows of joints 2|.

Each bearing member of the lower row of bearing members has twoextensions 33 which engage the outer ends of the bars I of the oppositeside members 3 of the bottom row of units and are welded theretopreferably by pressure welding in a manner similar to that as aforesaid,these outer ends of bars 1 being accordingly provided with the excessweldable metal M as shown in Fig. 5, thereby providing the welded joints34. The upper bearing members are provided with extensions 35 similar tothe extensions 33 and are similarly welded to the outer ends of the barsI of the upper row of units, thereby providing the welded joints 36.Extensions 33 and 35 will accordingly be provided with excess weldablemetal similar to the bars I.

The welded joints 34 and 36 are in alignment with their respectivelyaligned rows of welded joints 2| which, as aforesaid, are in line withtheir correlated bolts 30. This provides a construction best suited toresist tension forces transmitted from the crank shafts to the bank ofunits, more particularly to the respective aligned rows of bars Iconnected together by aligned rows of welded joints 2|.

The ends of the bank of units are enclosed by end walls 31 which aresecured to the outer ends of the bars 6 of the end units in any desiredway, as by welding.

In the foregoing description the preferable way of welding the unitstogether has been set forth, namely by first forming the horizontallongitudinal rows and then welding these rows together. However the bankof units provides two series of rows of units, one series being thehorizontal longitudinal rows and the other series being vertical rows.If desired the units may be welded together by first forming thevertical rows and then welding these rows together. In forming thevertical rows care will be taken, when forming each row, that thecenters of the corresponding half cylindrical walls be in alignment.Further when the vertical rows are welded t0- gether the weldingpressure will be continued when welding one row to its adjacent row tocause the rows to be moved together until the center lines of the twoadjacent rows of half cylinders coincide.

Still another way of forming the bank of welded units is to weld theunits together to form blocks and then to weld the blocks together. Forexample, the blocks may be formed of four units, see for instance Fig.'7, but in forming the blocks, and also in welding the blocks together,the order of welding followed must be such that no welding is carriedout between bars 6 and between bars 1 at the same time for this is notpermissible.

While there has been hereinbefore described an approved embodiment ofthis invention, it will be understood that many and various changes andmodifications in form, arrangement of parts and details of constructionthereof may be made withoutdeparting from the spirit of the invention,and that all such changesan'd modifications as fall within the scope ofthe appended claims are contemplated as a part of this invention.

The invention claimed and desired to be secured by Letters Patent is:

l. A welded engine frame construction comprising a bank of integralunits, each of said units having two spaced opposite side members and across member connecting said side members, said units being disposed inrows superimposed one upon another, each of said rows having its sidemembers at each side thereof adjacent each other end to end and weldedtogether at the joints therebetween and having its cross membersdisposed in substantially the same plane providing a cross wall for saidconstruction, its said cross members being configured to provide aplurality of orifices, said orifices of each of said cross walls beingin alignment respectively with corresponding orifices of the other ofsaid cross walls, providing rows of orifices, each of said rows oforifices being adapted to receive an engine cylinder, adjacent rows ofunits being welded together at the joints between their correspondingside members, said side members at each side of said constructionproviding a side wall for said construction.

2. A welded engine frame construction comprising a bank of integralunits, each of said units having two spaced opposite side members and across member connecting said side members, said units being disposed inrows superimposed one upon another, each of said rows having its sidemembers at each side thereof adjacent each other end to end and weldedtogether at the joints therebetween and having its cross membersdisposed in substantially the same plane providing a cross wall for saidconstruction, its said cross members being configured to provide aplurality of orifices, said orifices of each of said cross walls beingin alignment respectively with corresponding orifices of the other ofsaid cross walls, providing rows of orifices, each of said rows oforidoes being adapted to receive an engine cylinder, adjacent rows ofunits being welded together at the joints between their correspondingside members providing rows of welded joints extending in the samedirection as said rows of orifices, said side members at each side ofsaid construction providing a side wall for said construction; and a rowof bearing blocks for a crank shaft extending in the same direction assaid rows of units, said row of blocks being disposed at an outer row ofsaid rows of units, each of said blocks being opposite two of saidopposite, side members of said outer row and welded thereto at itsjointures therewith, said welded jointures being each in line with a rowof said rows of welded joints.

3. A welded engine frame construction comprising a bank of integralunits, each of said units having two spaced opposite side members and across member connecting said side members, said units being disposed inrows superimposed one upon another, each of said rows having its sidemembers at each side thereof adjacent each other end to end and weldedtogether at the joints therebetween and having its cross membersdisposed adjacent each other end to end in substantially the same planeproviding a cross wall for said construction, its said cross membersbeing configured to provide a plurality of orifices disposed, eachcrosswise of the adjacent two oppositely disposed welded joints, saidorifices of each of said 'cross walls being in alignment reweldedtogether at the joints between their corresponding side members, saidside members at ,having two spaced opposite side members ofcrossbar-like structure and a cross member connecting said side members,said units being spcctively with corresponding orifices of the otherdisposed in rows superimposed one upon another, each of said rows havingits side members at each side thereof adjacent each other end to end andwelded together at the joints therebetween and having its cross membersdisposed adjacent each other end to end in substantially the same planeproviding a cross wall for said construction, said row cross membersbeing recessed at their opposed ends to provide a plurality of orifices,said orifices of each of said cross walls being in alignmentrespectively with corresponding orifices of the other of said crosswalls providing rows of orifices, each of said rows of orifices beingadapted to receive an engine cylinder, adjacentrows of units beingwelded together at the joints between their corresponding side members,said side members at each side of said construction providing a sidewall for said construction, said cross bar structures cooperating toprovide rows of openings in said side walls.

5. A welded engine frame construction comprising a bank of integralunits, each of said units having two spaced opposite side members and across member connecting said side members, said units being disposed inrows superimposed one upon another, each of said rows having its sidemembers at each side thereof adjacent each other end to end andconnected together at the joints therebetween by welds producing flashesand having its cross members disposed adjacent each other end to end insubstantially the same plane providing a cross wall for saidconstruction, its said cross members being configured to provide aplurality of orifices disposed, each crosswise of the adjacent twooppositely disposed welds, said orifices of each of said cross wallsbeing in alignment respectively with corresponding orifices of the otherof said cross walls, providing rows of orifices, each of said rows oforifices being adapted to receive an engine cylinder, the defining wallof each orifice being in two sections, each in one of the two adjacentcross members, said two adjacent cross members being connected togetherat the joint therebetween by a weld producing a fiash, adjacent rows ofunits being connected together at the joints between their correspondingside members by welds producing flashes, said side members at each sideof said construction providing a side wall for said construction.

6. The combination, in an engine construction of the internal combustiontype constructed to receive a bank of cylinders, of cylinder enclosingmeans comprising a plurality of single section frame units arranged invertically aligned and horizontally aligned rows and providing internalchambers for the reception of cylinders, said frame units each havingintegrally formed spaced side wall members and a connecting crossmember, said connecting members having semi-cylindrical vertical wallsfor engaging sides of said cylinders, said units being permanentlywelded together.

7. A welded multi-cylinder engine frame construction comprising alongitudinal row of crank shaft supports, each having a half bearing andtwo transversely spaced bolt holes, one at each side of the axis of saidhalf bearing; and a row of units in line with each of said supports,each of said units having opposite side members connected by alongitudinal cross member, each of said side members being cross-shapedand having a longitudinal bar-like part integral with said cross memberand an intersecting tension bar-like part at right angles thereto, saidtension parts of corresponding side members of each of said rows ofunits being welded together and to said support aligned therewith inline with the correlated bolt hole thereof, adjacent longitudinalbar-like parts being welded together with their cross members alignedand configured to provide openings for receiving said cylinders.

8. A welded opposed piston multi-cylinder engine frame constructioncomprising two spaced longitudinal rows of crank shaft supports, eachhaving a half bearing and two transversely spaced bolt holes, one ateach side 'of the axis of said half bearing; and a row of units betweenand in line with corresponding supports of each of said rows ofsupports, each of said'units having opposite side members connected by alongitudinal cross member, each of said side members being cross-shapedand having a longitudinal bar-like part integral with said cross memberand an intersecting tension bar-like part at right angles thereto, saidtension parts of corresponding side 10 members of each of said rows ofunits being welded together and to said supports aligned there with inline with the correlated bolt holes thereof, adjacent longitudinalbar-like parts being welded together with their cross members alignedand configured to provide openings for receiving said cylinders.

EVERETT CHAPMAN.-

REFERENCES CITED The following references are of record in the file ofthis patent:

UNITED STATES PATENTS Number Name Date 2,280,016 Werdehofi Apr. 14, 19422,030,995 Loefiler Feb. 18, 1936 112,084 Smith Feb. 21, 1871 1,818,752Rabbidge Aug. 11, 1931 2,078,056 Chapman Apr. 20, 1937 2,159,006 ChapmanMay 23, 1939 2,246,857 Owens et al. June 24, 1941 FOREIGN PATENTS NumberCountry Date 10,948 British 1894 146,355 Swiss July 1, 1931

